System and method for manufacturing face masks with elasticized straps and product

ABSTRACT

A method of manufacturing a face mask comprises coupling at least one tensioned elastic structure to at least one web material to form a continuous elastic strap, advancing the continuous elastic strap in a machine direction, coupling the continuous elastic strap to a multi-layer mask web traveling in the machine direction to form a continuous face mask composite structure, and cutting the continuous face mask composite structure to define a plurality of discrete face masks. The multi-layer mask web comprises an inner web layer, an outer web layer, and a filter layer positioned therebetween.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/704,074, filed 16 Mar. 2020, the disclosure ofwhich is incorporated herein in its entirety.

BACKGROUND OF THE INVENTION

Embodiments of the present invention relate to face masks and, moreparticularly, to high speed automated production of face masks.

BRIEF STATEMENT OF THE INVENTION

Embodiments of the present invention are directed to systems, apparatus,and methods for making a face mask. More specifically, embodiments ofthe present invention are directed to a method for making a face maskthrough high speed automated production, a system for practicing themethod, and a product made by the method.

In accordance with one aspect of the invention, a method ofmanufacturing a face mask includes coupling at least one tensionedelastic structure to at least one web material to form a continuouselastic strap, advancing the continuous elastic strap in a machinedirection, coupling the continuous elastic strap to a multi-layer maskweb traveling in the machine direction to form a continuous face maskcomposite structure, the multi-layer mask web comprising an inner weblayer, an outer web layer, and a filter layer positioned therebetween,and cutting the continuous face mask composite structure to define aplurality of discrete face masks.

In accordance with another aspect of the invention, a face mask includesa multi-layer mask panel comprising an inner web layer, an outer weblayer, and at least one filter layer positioned therebetween and atleast one elastic strap coupled to the multi-layer mask web, the atleast one elastic strap comprising at least one elastic structurecoupled between a first web layer and a second web layer.

In accordance with another aspect of the invention, an apparatus formanufacturing a plurality of face masks includes at least one strapbonding unit configured to couple at least one tensioned elasticstructure to at least one web material to form a continuous elasticstrap and a feeding unit configured to advance the continuous elasticstrap in a machine direction. The apparatus also includes a mask bondingunit configured to couple the continuous elastic strap to a multi-layermask web traveling in the machine direction to form a continuous facemask composite structure, the multi-layer mask web comprising an innerweb layer, an outer web layer, and a filter layer positionedtherebetween. The apparatus further includes a cutting unit configuredto cut the continuous face mask composite structure to define aplurality of discrete face masks.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate embodiments presently contemplated for carryingout the invention.

In the drawings:

FIG. 1 is a schematic view of a portion of the manufacturing line forforming face masks according to an embodiment of the invention.

FIGS. 1A and 1B are schematic views of portions of the manufacturingline of FIG. 1 according to alternative embodiments of the invention.

FIG. 2 is a flowchart illustrating a method for making a face maskaccording to an embodiment of the invention.

FIGS. 3-9 are systematic diagrams illustrating the multi-layer mask webof FIG. 1 during the manufacturing process according to embodiments ofthe invention.

FIG. 10 is a schematic view of an individual face mask unit produciblevia the manufacturing line and method of FIGS. 1 and 2 according to anembodiment of the invention.

FIG. 11-14 are side plan views of an individual face mask unitproducible via the manufacturing line and method of FIGS. 1 and 2according to embodiments of the invention.

FIG. 15 is a schematic diagram of an elasticized strap web withdeactivation zones according to an embodiment of the invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide for a system and method forhigh speed automated production of face masks.

Although the disclosure hereof is detailed and exact to enable thoseskilled in the art to practice the invention, the physical embodimentsherein disclosed merely exemplify the invention which may be embodied inother specific structures. While the preferred embodiment has beendescribed, the details may be changed without departing from theinvention, which is defined by the claims.

As illustrated in FIG. 1 , a schematic view of a portion of amanufacturing line 100 for forming face masks according to an embodimentof the invention is shown. FIG. 2 illustrates a flowchart illustrating amethod 200 for making face masks according to an embodiment of theinvention. Referring to both FIGS. 1 and 2 , a plurality of bendablestrips 102 is supplied (step 202 of FIG. 2 ) from a supply spool 104 ofbendable material such as metal. Each bendable strip 102 may be cut orotherwise separated from the supply spool 104 by a separator unit 106such as a slip cut unit or other type of spacing and cutting unit. In analternative embodiment where bendable strips 102 are provided indiscrete form, the separator unit 106 may be omitted.

The bendable strips 102 are provided to a multi-layer mask web 108 thatincludes an outer layer 110, a filter layer 112, and an inner layer 114stacked together (step 204 of FIG. 2 ). As non-limiting examples, outerand inner layers 110, 114 may include nonwoven materials, wovenmaterials, films, foams, and/or composites or laminates of any of thesematerial types. In the embodiment illustrated in FIG. 1 , the outer andinner layers 110, 114 are separate webs. However, embodiments of theinvention contemplate that the outer and inner layers 110, 114 may beformed from a single web folded about the filter layer 112. In addition,the filter layer 112 may include single or multiple layers of filtermaterial that may be flat or may have folds or pleats formed therein.The bendable strips 102 may be positioned between the outer layer 110and filter layer 112 (as illustrated in FIG. 1 ), between the filterlayer 112 and inner layer 114, between multiple filter layers 112, or tothe outward-facing surface of inner layer 114. An adhesive may beoptionally applied from an adhesive applicator 116 directly to eachbendable strip 102 or to one of the layers to which it is beingsupplied.

As illustrated, the multi-layer mask web 108 includes the outer layer110, the filter layer 112, and the inner layer 114. Optional materialssuch as foam or other types of padding 118 may be included adjacent tobendable strip 102 either externally (as shown; step 206 of FIG. 2 ) orinternally to increase the comfort of the wearer of the mask.

In one embodiment, the outer layer 110 may be wider than the inner layer114 such that one or both of the longitudinal edges 122, 124 of theouter layer 110 extend beyond the longitudinal edges 126, 128 of theinner layer 114. Alternatively, one or both of the longitudinal edges126, 128 of the inner layer 114 may be wider than the correspondingedges 122, 124 of the outer layer 110. Accordingly, an optional edgefolder 120 may fold the extending longitudinal edges 122-128 to overlapthe longitudinal edges 122-128 of the opposite layer (step 208 of FIG. 2).

The multi-layer mask web 108 is provided to an edge sealer 130 so thatthe outer and inner layers 110, 114 may be joined or sealed together(step 210 of FIG. 2 ). In a preferred embodiment, the sealing of theouter and inner layers 110, 114 locks the filter layer 112 between theouter and inner layers 110, 114 so that its position remains fixed.Alternatively, the position of the filter layer 112 may be fixed throughother methods such as adhesive.

In one embodiment, the outer and inner layers 110, 114 are joined orsealed together using a bonding apparatus using any known ultrasonicwelding system in alternative embodiments, including, as non-limitingexamples, a rotary ultrasonic welding system or a blade ultrasonicwelding system. For example, a rotary anvil and an ultrasonic fixedblade horn, also known as a sonotrode, cooperate with each other to bondthe outer and inner layers 110, 114. Alternative embodiments may includemultiple fixed blade horns or one or more rotary horns.

The ultrasonic emission of energy from the edge sealer 130 isconcentrated at specific bond points where frictional heat fuses thelayers of web together without the need for consumable adhesives. Whilethe edge sealer 130 may include an ultrasonic bonding assembly thatultrasonically fuses layers of web together as described herein, it iscontemplated that the techniques described herein may be extended to anyother known welding or bonding techniques that fuse together two or morematerial layers including ultrasonic, thermal, or pressure bondingtechniques and various other forms of welding known in the industry.

Alternatively, the edge sealer 130 may include an adhesive applicatorand one or more rollers configured to apply adhesive or glue between theouter and inner layers 110, 114 and to apply pressure thereto to jointhe outer and inner layers 110, 114 together.

Alternatively, the edge sealer 130 may include a thermal bonding unit(not shown) configured to heat one or both of the outer and inner layers110, 114 and press the layers 110, 114 together causing the outer andinner layers 110, 114 to be joined together.

It may be desirous to have the speed or feed rate of the multi-layermask web 108 changed to a slower speed in locations where bonding orsealing of the outer and inner layers 110, 114 is to occur. In thiscase, a system configured to selectively decrease the feed rate of themask web 108 at the bond location may be used, such as, for example,multiple festoon accumulators may be used to slow the web to a bondingvelocity in a manner disclosed in U.S. Pat. No. 10,537,479, issued toCurt G. Joa, Inc. of Sheboygan Falls, Wis. and which is incorporatedherein by reference in its entirety.

In an embodiment where it is desirable to remove one or more portions ofthe longitudinal edges 122-128 extending beyond bond joints between theouter and inner layers 110, 114, an optional trimmer 132 may slit themulti-layer mask web 108 to separate undesirable portions therefrom tobe discarded (step 212 of FIG. 2 ).

Downstream of the edge sealer 130 in a machine direction 134, a pleatfolder 136 forms pleats (step 214 of FIG. 2 ) in the multi-layer maskweb 108 that allow the web 108 to be stretched to increase a coveringarea for a user's face. An optional patch placement assembly 138 mayattach (step 216 of FIG. 2 ) reinforcement patches adjacently to thelongitudinal edges of the multi-layer mask web 108 at the attachmentzones to which the elastic straps disclosed herein will be affixed. Theoptional reinforcement patches may be applied, for example, to the innerlayer 114 to reinforce the coupling of the elastic straps to themulti-layer mask web 108. Manufacturing line 100 may also include one ormore optional edge wrap units (not shown) configured to wrap materialabout one or both lateral edges of the multi-layer mask web 108.

An end seal unit 140 receives the multi-layer mask web 108 and seals orjoins the outer and inner layers 110, 114 together (step 218 of FIG. 2 )in an end seal location extending in a cross-machine direction 142 atlocations along the multi-layer mask web 108 corresponding to separationzones from which individual masks may be separated into individualunits. The end seal locations overlap and extend away from theircorresponding separation zones such that when an individual mask unit isseparated from the web 108, the joint of the outer and inner layers 110,114 created by the separated end seal location forms an end edge seal.

In a different portion of manufacturing line 100, an elasticized strapweb 144 is formed to provide elastic straps to be attached to themulti-layer mask web 108 to form straps stretchable around the head of auser to keep the mask unit in place. As shown, the elasticized strap web144 may be simultaneously created with the creation of the multi-layermask web 108. Alternatively, the elasticized strap web 144 may besupplied from a spool where the elasticized strap web 144 has beenpreviously created in a prior process. In the embodiment shown, a strapweb 146 is provided (step 220 of FIG. 2 ), and a one or more tensionedelastic strands or structures 148 are joined (step 222 of FIG. 2 ) tothe strap web 146, in one embodiment, by adhesive applied from anadhesive applicator 150 before or after the elastic strands are broughtnext to the strap web 146. While three elastic strands 148 areillustrated in FIG. 1 , embodiments of the invention contemplate thatany number of elastic strands may be used including a single strand. Inaddition or alternatively thereto, elastic film or other stretchablematerials such as rubber may be used.

In the case where the elastic straps are formed from a single layer ofstrap web material 146 as illustrated, a folder 152 may fold (step 224of FIG. 2 ) one portion of the strap web 146 over another to createinner and outer layers of strap web material between which the pluralityof elastic strands 148 is positioned. In an embodiment not usingadhesive, a non-adhesive bonding unit 154 (shown in phantom) may be usedin place of the adhesive applicator 150 to create a glue-less elasticstrap. The non-adhesive bonding unit 154 may utilize any known weldingor bonding techniques that fuse together two or more material layerswithout the use of adhesive, including sonic, thermal, or pressurebonding techniques and various other forms of welding known in theindustry. In other words, the non-adhesive bonding unit 154 may be anultrasonic bonding unit, a thermal bonding unit, or a pressure bondingunit, according to alternate embodiments. According to one non-limitingembodiment, non-adhesive bonding unit 154 may be configured in a similarmanner as any of the bonding units disclosed in U.S. Ser. Nos.16/260,259, 16/717,186, and 16/721,414 filed by Curt G. Joa, Inc. ofSheboygan Falls, Wis., the disclosures of which are incorporated hereinby reference in their entireties.

In the embodiment shown, a single assembly line for forming elasticizedstrap web 144 is used to form and split (step 226 of FIG. 2 ) theelasticized strap web 144 into two or more elastic straps by acutter/slitter 156. However, it is contemplated that multiple assemblylines may be used for creating corresponding multiple lines ofelasticized strap webs 144. In this case, the cutter 156 may beeliminated. Furthermore, it is contemplated that the cutter/slitter 156may be omitted in embodiments where a single, wide elastic strap may beused to secure the individual mask unit to the user wherein the singlestrap is attached to the mask at the side edges of both the top andbottom portions of the mask.

Manufacturing line 100 may further include an optional frictionenhancing unit 153 downstream from the folder 152. In one embodiment,unit 153 may be a cut-and-place unit that cuts and positions patches ofmaterial on the elasticized strap web 144 that enhance the friction ofthe strap web 144 and aid in maintaining the straps in position when thecompleted mask is in use. These patches of material may be secured tothe elasticized strap web 144 via adhesive, sonic, thermal, or pressurebonding, or any other known securement means. In alternativeembodiments, unit 153 may be a feed unit that couples a continuous webof friction-enhancing material to the surface of the strap web 144. Inyet other embodiments, the frictional properties of the strap web 146may be enhanced via application of a coating or surface treatment of thematerial itself.

Application of the elastic strands 148 to the strap web 146 occurs whilethe elastic strands 148 are in a stretched state. The result is anelasticized strap web 144. The tension in the elasticized strap web 144is relaxed or partially relaxed prior to its attachment to themulti-layer mask web 108. In one embodiment, the manufacturing speed ofthe elasticized strap web 144 is faster than the manufacturing speed ofthe multi-layer mask web 108. For example, the manufacturing speed ofthe elasticized strap web 144 may be 900-1000 ft./min. while themanufacturing speed of the multi-layer mask web 108 may be 300 ft./min.Thus, when in a relaxed state matching the length of the mask, theelasticized strap web 144 may offer a stretch of up to three times thelength of the mask.

Therefore, in order to attach the elasticized strap web 144 in a relaxedor partially-relaxed state to the multi-layer mask web 108, themanufacturing speed of the elasticized strap web 144 must be slowed downto correspond with the manufacturing speed of the multi-layer mask web108. A retraction assembly 158 retards (step 228 of FIG. 2 ) theelasticized strap web speed prior to the attachment of the elasticizedstrap web 144 to the multi-layer mask web 108. In one embodimentillustrated in FIG. 1A, the retraction assembly 158 includes a pluralityof rollers 160 arranged in an “s-wrap” configuration configured to allowthe speed of the elasticized strap web 144 to decrease between rollers160. Two or more rollers 160 may be used to retard the elasticized strapweb speed. Rollers 160 may be powered or free-rolling. In anotherembodiment illustrated in FIG. 1B, multiple pairs of nip rollers 162,164 may be used and actively controlled to slow down the manufacturingspeed of the elasticized strap web 144. For example, nip rollers 162 maybe controlled to reduce the speed of the elasticized strap web 144 to aspeed half of the difference (e.g., 600 ft./min. using the examplenumbers above) between the elasticized strap web speed and themulti-layer mask web speed. Nip rollers 164 may then be used to reducethe speed of the elasticized strap web 144 to a speed substantiallymatching the multi-layer mask web speed. It is contemplated that morepairs of nip rollers may be used to create more slowdown stages ifdesired.

Downstream of the end seal unit 140, the one or more continuouselasticized strap webs 144 are brought together with the multi-layermask web 108, while the one or more continuous elasticized strap webs144 and the multi-layer mask web 108 are traveling in the machinedirection 134, and provided to a strap bonding module 166 that bonds(step 230 of FIG. 2 ) the one or more elasticized strap webs 144 inattachment zones or bond sites 805 (FIG. 8 ) that are spaced apart inthe machine direction 134 and correspond with the end seal locations 700(FIG. 7 ) sealed by the end seal unit 140. Strap bonding module 166 maybe similar to any of the embodiments described above for edge sealer 130or may include other types of attachment methods including, for example,stapling. In the case where the strap bonding module 166 adhesivelyjoins the one or more elasticized strap webs 144 to the multi-layer maskweb 108, an adhesive applicator 168 may apply adhesive for theattachment. The one or more elasticized strap webs 144 are positionedalong the multi-layer mask web 108 so that both webs 108, 144 runtogether in the machine direction 134 for attachment. The straps, whenbound in this manner, extend along the length direction 807 (FIG. 10 )of the individual mask units 172 (FIG. 10 ) when separated rather thanalong the width direction 809 (FIG. 10 ) as known in the art.

After the one or more elasticized strap webs 144 are bonded with themulti-layer mask web 108, a cutting assembly 170 forms masks (step 232of FIG. 2 ) from the resulting continuous face mask composite structure234 in preparation for packaging. Cutting assembly 170 may have a knifeto completely cut through the combined webs 108, 144 to individualizediscrete mask units 172 at the separation zones or may have aperforation unit that forms perforations through the combined webs 108,144 to apply a perforation along the separation zones that allows an enduser to tear individual masks from a continuous mask web. Thereafter,the individualized mask units (or the perforated mask web) are providedto a packaging unit 174 for packaging the individual orperforation-formed masks as desired. For example, the masks may beindividually packed or bagged or boxed as a group of masks.

Referring to FIG. 3 , a schematic diagram illustrating the multi-layermask web 108 after the step 208 of folding the longitudinal edges 122,124 of the outer layer 110 over the inner layer 114 is shown. FIG. 4illustrates a schematic diagram showing the multi-layer mask web 108after the step 210 of edge sealing the longitudinal edges 122-128 of theouter and inner layers 110, 114. Attachment zones 400 of adhesive orindividual ultrasonic bond points, for example, are shown. Asillustrated, additional attachment zones 402 may be positionedadjacently to ends of the bendable strips 102 to further secure againstmovement along the length direction of the individual masks.

Referring to FIG. 5 , a schematic diagram illustrates the multi-layermask web 108 after the step 214 of forming pleats 500 therein. FIG. 6illustrates a schematic diagram showing the multi-layer mask web 108after the optional step 216 of placing reinforcement patches 600. Whilepairs of patches 600 are illustrated on opposite sides of themulti-layer mask web 108, a single patch 600 may be placed across thewidth of the multi-layer mask web 108 or a subportion of the width, suchas in a patch extending through the central section of the mask web 108,in other embodiments.

Referring to FIG. 7 , a schematic diagram illustrates the multi-layermask web 108 after the step 218 of joining the outer and inner layers110, 114 together at end seal locations 700. FIG. 8 illustrates aschematic diagram showing the resulting continuous face mask compositestructure 234 after the step 230 of bonding separated elasticized straps800, 802 to the multi-layer mask web 108. As shown in FIG. 8 , theseparated straps 800, 802 are bonded to the multi-layer mask web 108 atlocations adjacent the respective top longitudinal edge 801 and thebottom longitudinal edge 803 of the multi-layer mask web 108. FIG. 9illustrates a schematic diagram showing the separation zones 900 in thecontinuous face mask composite structure 234 along which the continuousface mask composite structure 234 is to be cut to individualize discretemask units 172 (FIG. 10 ) or along which the continuous face maskcomposite structure 234 is to be perforated as described above.

FIG. 10 provides a top plan view of an individual mask unit 172 withelasticized straps 1000, 1002 corresponding respectively to separatedelasticized straps 800, 802 of FIG. 8 . Referring to FIG. 11 , a sideplan view of the individual mask unit 172 is illustrated showingelasticized strap 1000 in a relaxed state. As shown in FIG. 11 , theelasticized strap 1000 has a ruffled appearance in the relaxed state dueto the gathering of strap web 146. FIG. 12 illustrates the elasticizedstrap 1000 in a stretched state to allow the elasticized strap 1000 tobe positioned around the head of a user. As previously discussed, thelength of the elasticized strap 1000 in the stretched state asillustrated in FIG. 12 may be, for example, three times the length ofthe elasticized strap 1000 in the un-stretched or relaxed state asillustrated in FIG. 11 . Other ratios of the length of the elasticizedstrap 1000 in its stretched state to its relaxed state are available,however, and contemplated herein. For example, an elasticized strap 1000formed from the elasticized strap 800 may have a different stretch ratiothan elasticized strap 1002 formed from the elasticized strap 802 on thesame discrete mask 172. One may have a 3:1 ratio while the other may bedifferent such as a 2:1 ratio. In addition, an elasticized strap 1000formed from the elasticized strap 800 may have a different attachmenttension to the mask 172 than elasticized strap 1002 formed from theelasticized strap 802 on the same discrete mask 172.

In an alternative embodiment, FIG. 13 illustrates a side plan view ofthe individual mask unit 172 where the length of the mask is longer thanthe length of the elasticized strap 1000 in its relaxed state. As shown,the multi-layer mask web portion of the mask unit 172 may be folded inpreparation for packaging to account for its longer length compared withthe length of the elasticized strap 1000. In another embodiment shown inFIG. 14 , the length of the elasticized strap 1000 in its relaxed stateis longer than the length of the mask unit 172. Accordingly, theelasticized strap 1000 may be folded if desired to account for itslonger length for packaging.

FIG. 15 illustrates a schematic diagram of an embodiment of theelasticized strap web 144 in either an adhesive-based construction or anadhesive-less elastic entrapment construction. As shown, deactivationzones 1400 may be formed by not applying adhesive or not formingentrapment bonds in areas 1400 to have elastic deactivation and breakingthe elastic threads 148 that span the areas 1400, causing the elasticthreads 148 to retract toward opposite sides of the deactivation zone1400 to the point where the elastic threads 148 are trapped by eitheradhesive or entrapment bonds. The elastic threads 148 may be broken bybeing cut with a cutting unit (not shown) configured to cut the elasticthreads 148 using a knife or by being pinched to a breaking point with acrushing apparatus. Adhesive-less elastic entrapment constructioninvolving entrapment bonds and deactivation zones is described in U.S.Publication No. 2019/0234606 and assigned to Curt G. Joa, Inc. ofSheboygan Falls, Wis., which is incorporated herein by reference in itsentirety.

Embodiments of the invention described herein provide a number ofimprovements over prior art face masks. The resulting mask structureincludes a ruffled elastic strap that is more comfortable to wear andmore breathable. The disclosed methods of manufacturing the elasticstraps facilitates forming straps with adjustable tension to create animproved fit. The mask is held in place while in use due to the ruffledprofile of the strap alone or in combination with otherfriction-enhancing materials or surface textures. The disclosed methodof manufacture also permits masks to be formed at a higher speed thatprior art methods, as the masks do not need to be turned 90 degreesprior to attaching the straps.

While the invention has been described in detail in connection with onlya limited number of embodiments, it should be readily understood thatthe invention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description butis only limited by the scope of the appended claims.

What is claimed is: 1-23. (canceled)
 24. A method of manufacturing aface mask, comprising: a. forming a continuous multi-layer mask web,including: a1. providing an inner web layer, an outer web layer, and atleast one filter layer positioned therebetween, from correspondingsupplies of mask material; a2. bonding together the inner web layer, theouter web layer, and at least one filter layer; and a3. forming aplurality of separation zones laterally across a width of the mask weband perpendicular to a machine direction; b. forming a continuoustensioned elastic strap structure, including: b1. providing a supply ofelastic material; b2. tensioning the elastic material; b3. coupling theelastic material between a first strap web layer and a second strap weblayer; and b4. operatively non-adhesively bonding the tensioned elasticmaterial to the first and second strap web layers while the elasticmaterial is under tension; c. operatively coupling a cut portion of thecontinuous elastic strap structure to a corresponding portion of themulti-layer mask web; and d. repeatedly cutting the continuousmulti-layer mask web along the separation zone to cut a plurality ofdiscrete face masks from the continuous mask web.
 25. The method ofclaim 24, wherein forming the continuous multi-layer mask web andforming the continuous tensioned elastic strap structure occursimultaneously or occur sequentially.
 26. The method of claim 24,wherein the cut portion of the continuous elastic strap structure isoperatively coupled to the multi-layer mask web when the elastic strapstructure is in a de-tensioned state.
 27. The method of claim 24,further comprising reducing a feed rate of the continuous elastic strapstructure prior to coupling the elastic strap structure to themulti-layer mask web.
 28. The method of claim 24, further comprisingoperatively coupling a friction-enhancing material to the continuouselastic strap structure.
 29. The method of claim 24, wherein the elasticstrap structure is operatively coupled to the multi-layer mask web withone of an adhesive material, an ultrasonic bond, thermal bond, and/or apressure bond.
 30. The method of claim 24, further comprising coupling acut portion of the continuous elastic strap structure to the multi-layermask web at a plurality of bond sites on the multi-layer mask web,wherein the bond sites are spaced apart in the machine direction. 31.The method of claim 24, further comprising: providing a slitting unit tosplit the continuous elastic strap structure into a plurality ofparallel continuous elastic strap portions; advancing the plurality ofcontinuous elastic straps portions in the machine direction; cuttingeach of the plurality of continuous elastic straps portions into a cutstrap having a predetermined length; and operatively coupling each ofthe plurality of cut straps to the multi-layer mask web.
 32. The methodof claim 24, wherein cutting the continuous multi-layer mask webincludes creating perforation cuts along a width of the multi-layer maskweb, spaced apart in the machine direction.
 33. The method of claim 24,wherein the supply of elastic material is formed with one or moreelastic strands of material.
 34. The method of claim 24, furthercomprising ultrasonically bonding the tensioned elastic material to thefirst and second strap web layers.
 35. A method of manufacturing a facemask, comprising: a. forming a continuous multi-layer mask web,including: a1. bonding together an inner web layer, an outer web layer,and at least one filter layer positioned therebetween; a2. forming aplurality of separation zones laterally across a width of the bondedmask web and perpendicular to a machine direction; b. forming acontinuous tensioned elastic strap structure, including: b1. positioningan elastic material between a first strap web layer and a second strapweb layer; and b2. operatively non-adhesively bonding the elasticmaterial to the first and second strap web layers while the elasticmaterial is under tension; c. operatively coupling a portion of thecontinuous elastic strap structure to a corresponding portion of themulti-layer mask web; and d. repeatedly cutting the continuousmulti-layer mask web along the separation zone to cut a plurality ofdiscrete face masks from the continuous mask web.
 36. The method ofclaim 35, wherein forming the continuous multi-layer mask web andforming the continuous tensioned elastic strap structure occursimultaneously or occur sequentially.
 37. The method of claim 35,further comprising cutting the continuous elastic strap structure toform a strap portion having a predetermined length, and operativelycoupling the strap portion to the multi-layer mask web.
 38. The methodof claim 35, further comprising reducing a feed rate of the continuouselastic strap structure prior to coupling the elastic strap structure tothe multi-layer mask web.
 39. A face mask comprising: a discrete facemask panel cut from a continuous multi-layer mask web, wherein the maskpanel is cut from the continuous mask web along corresponding separationzones formed on the continuous mask web, the separation zones formedperpendicular to a machine direction at predetermined intervals alongthe machine direction; the discrete face mask panel having inner weblayer, an outer web layer, and at least one filter layer therebetween;wherein the inner web layer, the outer web layer, and the at least onefilter layer are operatively bonded together; at least one elastic strapoperatively bonded at each end thereof to the discrete face mask panelat corresponding bonding sites disposed at opposite sides of the maskpanel; and the at least one elastic strap having an elastic materialnon-adhesively bonded between a first strap web layer and a second strapweb layer, wherein the elastic material is under tension during thebonding.
 40. The face mask of claim 39, wherein the at least one elasticstrap is operatively coupled to the face mask panel by at least one ofan adhesive material, an ultrasonic bond, thermal bond, and/or apressure bond.
 41. The face mask of claim 39, wherein the at least oneelastic strap comprises: a first elastic strap positioned adjacent afirst lateral edge of the mask panel; and a second elastic strappositioned adjacent a second lateral edge of the mask panel.
 42. Theface mask of claim 39, wherein the inner web layer and the outer weblayer comprise a nonwoven material.
 43. The face mask of claim 39,wherein the at least one elastic strap has a ruffled appearance in arelaxed state.
 44. The face mask of claim 39, further comprising afriction-enhancing material operatively bonded to the at least oneelastic strap.
 45. The face mask of claim 39, wherein the at least oneelastic strap further comprises: a first elastic strap positionedadjacent a top longitudinal edge of the mask panel, the first elasticstrap having a first end coupled to the mask panel adjacent a first sideedge thereof and a second end coupled to the mask panel adjacent asecond side edge thereof; and a second elastic strap positioned adjacenta bottom longitudinal edge of the mask panel, the second elastic straphaving a first end coupled to the mask panel adjacent the first sideedge and a second end coupled to the mask panel adjacent the second sideedge.
 46. An apparatus for manufacturing a plurality of face masks,comprising: a mask-forming unit configured to receive a continuoussupply of an outer web layer material, an inner web layer material, anda filter layer material, from respective supply rolls of said material;an edge sealer unit located downstream from the mask-forming unit, theedge sealer unit non-adhesively sealing the filter layer materialbetween the outer web layer material and the inner web layer material,to form a continuous plurality of mask panels, each mask panel separatedby a separation zone; a strap tensioning unit configured receive acontinuous supply of an elastic material and configured to tension theelastic material; a strap forming unit configured receive a continuoussupply of a strap web material and configured to non-adhesively bond thetensioned elastic material to the strap web material to form acontinuous elastic strap; a strap bonding unit configured tonon-adhesively bond a portion of the continuous elastic strap to aportion of each of the mask panels; and a mask cutting unit configuredto cut the continuous plurality of mask panels along the separation zoneto form a plurality of discrete face masks.
 47. The apparatus of claim46 further comprising a retraction assembly configured to adjust afeeding speed of the continuous elastic strap upstream of the strapbonding unit.
 48. The apparatus of claim 46 wherein the strap formingunit includes a strap folding unit configured to fold the strap webmaterial about the tensioned elastic material.
 49. The apparatus ofclaim 46 wherein the strap bonding unit is configured to couple a cutend of the continuous elastic strap to the mask panels at a bond site.50. The apparatus of claim 46 wherein the strap bonding unit isconfigured to couple a first strap portion cut from the continuouselastic strap, to a top longitudinal edge of the mask panel, andconfigured to couple a second strap portion cut from the continuouselastic strap, to a bottom longitudinal edge of the mask panel.